JP2006070908A - Vacuum heat insulating material and refrigerator - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide such structure in which a sheathing material is not damaged by a core material having a surface layer hardened by an inorganic binder of a vacuum heat insulating material or an edge and a ridge of the core material used by cutting to a predetermined dimension. <P>SOLUTION: The core material is composed of the core material 31 of a single layered fibrous material layered product, and a coating layer 32 of a flexible fibrous material. After the core material 31 is covered with the coating layer 32, the core material 31 is arranged in the sheathing material 33 having a deposited film layer 33f, etc. inside to manufacture the vacuum insulating material by decompressing and sealing the inside of the sheathing material 33. Since a workpiece particle 31a of the core material 31 hardened with the binder, and a foreign substance 31b are directly brought in contact with the sheathing material 33, the sheathing material 33 is not damaged, it becomes easy to handle in manufacturing process of the vacuum insulating material itself, and it is easy to handle in each manufacturing process at assembling the vacuum insulating material into a refrigerator box body and door, so that a highly reliable refrigerator can be manufactured. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a vacuum heat insulating material, a method for manufacturing the same, and a refrigerator using the vacuum heat insulating material.

  A conventional method for manufacturing a vacuum heat insulating material is to fabricate a laminated fiber by laminating fiber materials into a predetermined shape, apply a binder diluted with water to at least one of the outer surfaces of the laminated fiber, and apply the laminated fiber coated with the binder to 100 The core material was produced by compressing the laminated fiber at a temperature of 100 ° C. or lower and further heating and compressing the compressed laminated fiber at a temperature of 100 ° C. or higher.

  Moreover, in the refrigerator using the conventional vacuum heat insulating material, the vacuum heat insulating material was stuck on the space formed by the outer box and the inner box, and the space other than the vacuum heat insulating material was filled with the foam heat insulating material. This vacuum heat insulating material is composed of a core material made of a fiber material and an outer cover material that has a laminate film including at least a gas barrier layer and a heat sealing layer and covers the core material to decompress the inside. The fiber material of the surface layer of the core material has an inorganic binder, and the fiber material of the inner layer has no inorganic binder or an inorganic binder at a lower concentration than the surface layer (for example, patent document) 1).

  The core material having such a structure can impart the rigidity of the core material to the portion where the binder concentration is high, and can make the heat insulating property responsible for the portion where the binder concentration is low, thereby reducing the solid heat conduction and improving the heat insulating performance. It is said.

Japanese Patent No. 3497500 (Pages 5-6, FIGS. 3 and 4)

  In the above prior art, since the inorganic binder is attached to the fiber material of the surface layer of the core material, the surface layer cured by the inorganic binder may damage the jacket material covering the surface layer. Among the manufacturing processes for manufacturing the vacuum heat insulating material, in the process of inserting the core material into the bag-shaped jacket material having the laminate film including the gas barrier layer, or after the core material is inserted into the bag-shaped jacket material In the process, a core material having a surface layer hardened by an inorganic binder may come into contact with the bag-like jacket material and damage the gas barrier layer of the bag-like jacket material.

  In order to reduce the manufacturing cost, a large plate-shaped core material is manufactured, and the core material is cut into a predetermined size to manufacture a plurality of core materials, or errors in manufacturing dimensions are reduced. Therefore, when the core material is cut into a predetermined size by post-processing after forming the core material, the core material surface is cured by an inorganic binder, so the corners and ridge lines of the core material after cutting There was a greater risk that the would become a knife edge and damage the gas barrier layer of the bag-shaped outer jacket material.

  FIG. 11 is a cross-sectional view showing the structure of a conventional core material. On the surface 2e of the core material 2 cured by the inorganic binder, material grains 2a, foreign matters 2b, and wrinkles 2c having large diameters and grains among the materials constituting the core material may occur. Since the core material 2 is hardened by the inorganic binder, the material particles 2a, the foreign matter 2b, and the wrinkle 2c may protrude from the surface 2e by the dimensions K1, K2, and K3. These raw material particles 2a, foreign matter 2b, and wrinkle 2c damage the outer cover material, and after a long period of time, gas may permeate through the damaged portion.

  An object of the present invention is to provide a structure in which a core material having a surface layer hardened by an inorganic binder of a vacuum heat insulating material or a corner or a ridge line of a core material used after being cut to a predetermined size does not damage an outer cover material.

  In order to achieve the above object, the present invention provides a vacuum heat insulating material comprising a core material and a jacket material covering the core material, wherein the core material is coated with a core material of a fiber material laminate and a flexible fiber material. A vacuum heat insulating material is proposed in which a core material formed by covering a core material with a coating layer is disposed in a jacket material.

  The present invention is also a vacuum heat insulating material comprising a core material and a jacket material covering the core material, wherein the core material is composed of a core material of a fiber material laminate and a covering layer of a flexible fiber material, We propose a vacuum heat insulating material in which a core material is a core material formed by applying an inorganic binder solution and heat-molded, and a core material formed by covering the core material with a coating layer is disposed in an outer cover material.

  The core material is composed of the core material of the fiber material laminate and the coating layer of the flexible fiber material, and the core material formed by covering the core material with the coating layer is disposed in the jacket material, so it is cured by the binder. It is possible to prevent the outer cover material from being damaged by the core material. Moreover, in the structure where the flexible coating layer covers the surface of the core material which is hardened by the binder and has an uneven surface, the flatness of the vacuum heat insulating material is easily obtained.

  A core material having a surface layer hardened by an inorganic binder is externally applied in a manufacturing process in which a core material that is hardened by a binder and the surface of the core material having an uneven surface is covered with a flexible coating layer and the core material is disposed in the outer shell material. Since it does not contact the workpiece, a vacuum heat insulating material is obtained in which the core does not damage the jacket.

  As a result of providing a flexible coating layer on the surface of the core material that is a strength member of the core material, the surface hardness of the core material including the coating layer is softened, and the surface hardness of the vacuum heat insulating material is softened, so the softened surface Improves impact resistance. Therefore, it is possible to obtain a vacuum heat insulating material that is easy to handle in the manufacturing process of the vacuum heat insulating material itself when the vacuum heat insulating material is incorporated into the refrigerator box or the door.

  Since the layer thickness of the coating layer using the flexible fiber material is 1 mm or more, a vacuum heat insulating material that prevents the outer cover material from being damaged by the core material cured by the binder can be provided.

  More specifically, when the thickness of the coating layer is set to 1 mm or more and a welded film layer having a thickness of 50 μm or less is employed, gas leakage from the welded film layer can be reduced, and the degree of vacuum is maintained over a long period of time. A high refrigerator can be provided.

  If the fiber material waste material after taking the material as the core material is heat-molded using a binder, the material yield is improved and the environmental load can be reduced.

  Vacuum heat insulating material that is easy to adjust to uneven surfaces and R-shaped material surfaces when combined with a coating layer using lightweight urethane with good surface flatness as a core material and waste urethane molded products that are produced when heat insulating boxes such as refrigerators are discarded. Is obtained. Moreover, recyclability improves by use of a waste urethane molding.

  If a thermal radiation pipe is provided between the outer plate and the vacuum heat insulating material, and the unevenness of the outer diameter of the thermal heat radiation pipe is absorbed by the flexible coating layer of the vacuum heat insulating material, the flatness of the vacuum heat insulating material Therefore, it is possible to provide a refrigerator in which a foamed heat insulating material such as urethane is less likely to enter between the vacuum heat insulating material and the outer plate, and the outer plate surface is less distorted.

  If there is a protrusion other than the vacuum heat insulating material in the vicinity of the vacuum heat insulating material and the coating layer is provided only on the surface of the core material or the corners or ridges where the protrusion may contact, the surface of the core material hardened by the binder Is covered with a flexible covering layer, so that even if the projection comes into contact with the vacuum heat insulating material, the flexible covering layer serves as a buffer member and hardly damages the outer cover material of the vacuum heat insulating material. In addition, since the coating layer is provided only on the surface, corners, or ridgelines of the core material with which the protrusions may come into contact, the production efficiency is good when producing a large area vacuum heat insulating material.

  When a vacuum heat insulating material is installed on the outer plate side in the heat insulating wall, and a coating layer is formed only on the side of the vacuum heat insulating material that contacts the outer plate, the flexible coating layer fits closely to the curved surface portion of the outer plate having a curved surface. Therefore, a refrigerator having a beautiful appearance design of the curved surface portion can be provided.

  The refrigerator of the present invention is a foam heat insulating material in the space after the vacuum heat insulating material having a step of attaching the adhesive member on the surface is installed in the heat insulating space forming the refrigerator box and the door using the adhesive member. Since the vacuum heat insulating material is fixed, it is possible to prevent the outer cover material from being damaged by the core material hardened by the binder and to provide a highly reliable refrigerator.

  Since the flexible coating layer covers the surface of the core material that is hardened by the binder and has irregularities on the surface, the flatness of the vacuum heat insulating material is ensured, and a foam heat insulating material such as urethane is provided between the vacuum heat insulating material and the outer plate. It is possible to provide a refrigerator that is hard to penetrate and has less distortion on the outer plate surface, and the degree of freedom in external design is increased.

  According to the present invention, it is possible to realize a structure in which a core material having a surface layer hardened by an inorganic binder of a vacuum heat insulating material or a corner or a ridge line of a core material used after being cut to a predetermined size does not damage an outer cover material.

  With reference to FIGS. 1-10, the vacuum heat insulating material by this invention, its manufacturing method, and the Example of a refrigerator are demonstrated.

(Example 1 of a refrigerator)
FIG. 1 is a longitudinal sectional view showing an embodiment of a refrigerator according to the present invention, and FIG. 2 is a transverse sectional view taken along the line AA of Embodiment 1 of the refrigerator according to the present invention.

  The refrigerator box 10 includes an outer plate 21 and an inner plate 12, and a vacuum heat insulating material 30 is attached to the outer plate side or the inner plate side of the space formed by the outer plate 21 and the inner plate 12. The space other than 30 is filled with the foam heat insulating material 13.

The refrigerator box 10 is formed by partitioning a refrigeration temperature chamber 14 and a freezing temperature chamber 15 having an ice making chamber and a freezing chamber.
A cooler 18 that cools the inside of the refrigerator to a predetermined temperature is connected to a compressor 20 by a pipe 19 and forms a part of a series of refrigeration cycles.
The blower 16 is supplied with power through the wiring cord 17 and circulates the cool air cooled by the cooler 18 in the refrigerator cabinet to maintain a predetermined low temperature.

  The vacuum heat insulating material 30 which is the object of the present invention is a vacuum heat insulating material having a lower thermal conductivity than the foamed heat insulating material 13 such as urethane. The vacuum heat insulating material 30 includes a core material 30a and a jacket material 33 having a gas barrier layer covering the core material 30a. The core material 30a is composed of a core material 31 whose surface is hardened by an inorganic binder and becomes a strength member, and a coating layer 32 that covers the surface of the core material 31 so that the jacket material 33 does not come into direct contact.

  The core material 31 is a plate-like fiber material with an inorganic binder such as boric acid or phosphoric acid, and the coating layer 32 is a flexible fiber material formed with a fiber material without a binder.

  The flexible coating layer 32 is formed by the binder so that the core material 31 cured by the binder and the jacket material 33 having the gas barrier layer are not in direct contact with each other, and even if the vacuum heat insulating material is externally loaded. The cured layer on the surface of the hardened core material 31 serves as a buffer material between the core material 31 and the jacket material 33 so that the jacket material 33 is not damaged.

  The locking tool 25 a is a rotation roller of a drawer rail (not shown) or a locking tool in the refrigerator cabinet, and the rotation roller and the locking tool 25 a are fixed to the reinforcing member 25. The reinforcing member 25 is a protrusion that is installed in a space formed by the outer plate 11 and the inner plate 12, and is installed in the vicinity of the vacuum heat insulating material 30.

  In the manufacturing process of the refrigerator box 10, first, the vacuum heat insulating material 30 is installed on the inner surface 21 a of the side plate 21 of the outer plate 11 with an adhesive member such as a hot melt adhesive or a double-sided adhesive tape.

  The inner plate 12 is incorporated in the side plate 21 on which the vacuum heat insulating material 30 is installed. For example, the flange 12a of the inner plate 12 is inserted into the front fitting portion 21a of the side plate 21 and fitted.

  A pipe 19 for the refrigeration cycle and a wiring cord 17 for the blower are installed on the back surface portion 12 b of the inner plate 12.

  The flange 22a of the back plate is inserted into the rear fitting portion 21b of the side plate 21, and the back plate 22 of the outer plate 11 on which the vacuum heat insulating material 30 is previously installed is fitted in another process.

  The box assembled so far is reinforced with a mold or the like, and the space formed between the outer plate 11 and the inner plate 12 is filled with foamed heat insulating material such as urethane at a predetermined temperature, and the box is cooled. The refrigerator box 10 is formed by incorporating 18 and the blower 16.

  Since the flexible coating layer 32 is cured by a binder or the like and covers the surface of the core material 31 having irregularities on the surface, the flatness of the vacuum heat insulating material can be easily obtained, and a compact refrigerator can be provided.

  In the structure in which the flexible coating layer 32 is disposed on the surface of the core material 31 that is a strength member of the core material 30a, the surface hardness of the core material including the coating layer is softened, the impact resistance is increased, and it is easy to handle during the manufacturing process. Vacuum insulation can be provided.

  Since the surface of the core material 31 hardened by the binder is covered with a flexible coating layer 32 without a binder, the reinforcing member 25, the front fitting portion 21a, the rear fitting portion 21c, the piping 19 of the refrigeration cycle, the wiring Even if a member such as the cord 17 comes into contact with the vacuum heat insulating material 30, the flexible covering layer 32 serves as a buffer member, and the vacuum heat insulating material 30 is prevented from being damaged.

That is, during the assembling work of the refrigerator box 10, the surface or corners of the vacuum heat insulating material, the ridgeline part 30 b and the front fitting part 21 b and the rear fitting part 21 c of the side plate, the piping 19 of the refrigeration cycle, the wiring cord 17 of the blower, Even if the reinforcing member 25 or the like comes into contact, the flexible coating layer 32 becomes a buffer member, and the outer covering material 33 of the vacuum heat insulating material is less likely to be damaged.
Therefore, the vacuum degree of the vacuum heat insulating material is hardly lowered, and a refrigerator structure having a vacuum heat insulating material having excellent thermal conductivity even after a long period of time can be provided.

  Instead of covering all the surfaces of the core material 31 with the flexible coating layer 32, the reinforcing member 25, the front fitting portion 21b and the rear fitting portion 21c of the side plate 21, the piping 19 of the refrigeration cycle, and the wiring cord of the blower If the flexible covering layer 32 is disposed only on the face or corner or the ridgeline 30b of the core material 31 that is expected to come into contact, the structure with good production efficiency even when the vacuum heat insulating material 30 with a large area is manufactured. become. Even in such a structure, even if the protrusions of the core material 31 cured by the binder come into contact with the vacuum heat insulating material 30, the coating layer 32 serves as a buffer member, and the damage to the vacuum heat insulating material 30 can be reduced.

  The core material 31 is not only a fiber material laminate, but also a waste fiber material molded product obtained by molding a fiber material waste material with a binder, and a board-like molded body made of continuous urethane. A waste urethane molded product obtained by molding waste urethane with a binder may be used.

  The covering layer 32 has a layer thickness of 1 mm or more and is formed of a flexible fiber material. Therefore, although the surface of the core material 31 using the fiber material laminate is cured by the inorganic binder, the coating layer 32 is formed of a flexible fiber material without a binder, for example. And has a buffering action.

(Example of vacuum insulation)
FIG. 3 is a cross-sectional view showing the structure of the vacuum heat insulating material according to the present invention.

  The vacuum heat insulating material 30 includes a core material 30a and a gas barrier outer covering material 33 that covers the core material 30a. The core material 30a is formed on the surface of the core material 31 and a core material 31 that is a strength member of the core material. It consists of the coating layer 32 which coat | covers the surface of the core material 31 so that the jacket material 33 may not contact directly.

  The core material 31 is a fiber material provided with an inorganic binder such as boric acid or phosphoric acid, and the coating layer 32 is a flexible fiber material having a buffering effect.

  The vacuum heat insulating material 30 is formed by depressurizing the inside covered with the gas barrier outer covering material 33 and the inside of the core material 30a to a predetermined degree of vacuum, and exhibits a predetermined heat insulating performance as a vacuum heat insulating material.

  The outer covering material 33 includes a surface protective film 33a formed of nylon resin or polyethylene terephthalate resin, a metal foil 33e such as aluminum having a good gas barrier property inside thereof, and a high density polyethylene resin or polyacrylonitrile resin inside thereof. It is formed by integrally laminating a welding film layer 33f that can be thermally welded.

  In some cases, the gas barrier property is further improved by interposing a metal deposition film 33b in which a metal such as aluminum is deposited on a support layer 33c such as a polyethylene terephthalate resin or a polypropylene resin between the surface protection film 33a and the metal foil 33e. .

  FIG. 4 is an enlarged cross-sectional view showing the structure of the main part of the vacuum heat insulating material of FIG.

On the surface 31e of the core material 31 cured by the inorganic binder, material grains 31a, foreign matter 31b, and wrinkles 31c having large diameters and grains among the materials constituting the core material are generated. Since the core material 31 is hardened by the inorganic binder, the material particles 31a, the foreign matter 31b, and the wrinkle 31c protrude from the surface 31e by the H1, H2, and H3 dimensions.
32 is a coating layer coated on the surface of the core material so that the core material 31 is not in direct contact with the jacket material 33. Since the coating layer 32 is formed of a flexible fiber material, the cured material grains 31a and The foreign matter 31b or the wrinkle 31c is configured so as not to damage the gas barrier layer of the covering material 33.
In other words, even if the material particles 31a, foreign matter 31b or wrinkle 31c cured by the binder protrude from the core surface 31e by the dimension H1, dimension H2, “dimension H3”, the flexibility is provided so that the protruding dimension can be absorbed. A thickness T1 of the covering layer 32 is set.

  The material particles 31a, foreign matters 31b, wrinkles 31c, etc. appearing on the surface of the core material are localized on the outer cover material 33 by atmospheric pressure, pressure applied during manufacture, or contact pressure from the outside during handling during assembly. The thickness T1 of the coating layer 32 is set so that the metal foil 33e does not impair the gas barrier property even if it is compressively deformed.

  FIG. 5 is a chart showing the characteristic values of the artificial mineral fiber heat insulating material, and shows examples of the dimensions H1, H2, and H3 of the material grains 31a, 31b, and 31c appearing on the surface 31e of the core 31.

  The core material 31 is made of “artificial mineral fiber heat insulating material” (JISA9504). Since the size distribution of the raw material grains 31a differs depending on the manufacturing method of “artificial mineral fiber heat insulating material”, the flame method and the centrifugal method are divided into three categories A, B, and C, and the ratio is expressed as a percentage (% ). A dimension H1, a dimension H2, and a dimension H3 of less than 10 μm are designated as category C, those having a dimension of 10 μm to 20 μm are designated as category B, and those having a dimension exceeding 20 μm are designated as category A.

  The largest protruding dimension such as a material grain is most often less than 10 μm, but in consideration of production efficiency, the maximum protruding dimension should be 20 μm or less.

  In addition, the use of “artificial mineral fiber heat insulating material” manufactured by a centrifugal method excellent in mass productivity can reduce the manufacturing cost of the vacuum heat insulating material.

  According to the experiments by the inventors, in order to absorb the dimensions H1, H2, and H3, the gas barrier property of the metal foil 33e can be maintained over a long period of time if the thickness T1 of the coating layer 32 is 1 mm or more. It was found that it was not damaged.

  Further, when the core material is cut and used after being molded, the burr due to cutting often exceeds the dimensions H1, H2, and H3. However, it has been found that if the thickness T1 of the covering layer 32 is 1 mm or more, the gas barrier property of the metal foil 33e is not impaired even if there is a burr.

  As shown in FIGS. 3 and 4, even if the raw material particles 31a, foreign matter 31b, and wrinkle 31c hardened by the binder protrude from the core surface 31e by the dimensions H1, H2, and H3, the protruding dimensions can be absorbed. Further, the thickness T1 of the flexible coating layer 32 is set, and the core material cured by the binder is not directly brought into contact with the outer jacket material. Therefore, during the manufacturing process of the vacuum heat insulating material itself, Even if the material is pressed against the core material, or even when the vacuum heat insulating material is incorporated into the refrigerator box or door, even if an external member comes into contact with the vacuum heat insulating material, the gas barrier property of the jacket material is impaired. There can be provided a vacuum heat insulating material and a refrigerator using the same.

  FIG. 6 is a chart comparing the characteristics of Example 1, Example 2 and Comparative Example 1 of the vacuum heat insulating material according to the present invention. The vacuum heat insulating material of the present Example was manufactured using the raw material of the division B of FIG.

  Example 1 in FIG. 6 uses a 15 μm nylon resin as a surface protective film, an aluminum metal vapor deposition film of 400 to 500 mm, a 12 μm polyethylene terephthalate resin as a support layer of the vapor deposition film, and an aluminum foil of 6 μm. A 50 μm high density polyethylene resin was used as the welding film layer. As a raw material for the flexible coating layer 42, “artificial mineral fiber heat insulating material” (JISA9504) manufactured by a centrifugal method was used, and the thickness of the surface layer was set to 1 mm.

  In order to verify that the gas barrier properties are not impaired over the long term, the initial value of the thermal conductivity and the sample after being left in the air at 70 ° C. for 4 months so that the deterioration of the thermal conductivity with time can be determined. Values were measured. The thermal conductivity was measured at an average temperature of 24 ° C. using a thermal conductivity measuring device HC-071 manufactured by Eihiro Seiki.

  In Example 2, a high-density polyethylene resin having a thickness of 20 μm was used as the welding film layer, and the other conditions were the same as those in Example 1.

  As shown in FIG. 6, the measured value after heating at 70 ° C. for 4 months is 7 to 8 mW / mK in both Examples 1 and 2, which is better than 9 to 11 mW / mK in Comparative Example 1. Met.

  According to the vacuum heat insulating material of the present invention, even if material particles, foreign matters, wrinkles or the like having large diameters or grains are generated on the surface of the core material of the vacuum heat insulating material, a knife edge is generated at the corner or ridge line of the core material 41. However, if the covering layer 42 having a layer thickness of 1 mm or more is formed of a flexible fiber material between the core material 41 and the covering material 43, the covering material 43 having the gas barrier layer will not be damaged. Even if it passes, the refrigerator containing the vacuum heat insulating material excellent in thermal conductivity is obtained.

  Further, if a covering layer 42 made of a flexible fiber material and having a layer thickness of 1 mm or more is provided, a knife can be applied to the corners and ridgelines of the core material even if the thickness of the welding film layer as the welding layer is reduced to 50 μm or less. Even if an edge occurs, the jacket material 43 having the gas barrier layer is not damaged, so that a refrigerator including a vacuum heat insulating material having excellent thermal conductivity can be provided even after a long period of time.

  If the thickness of the welded film layer 43f is reduced, long-term gas leakage from the welded portion of the welded film layer 43f is reduced, so that a vacuum heat insulating material with excellent thermal conductivity can be obtained even after a long period of time.

(Example 2 of a refrigerator)
FIG. 7 is a cross-sectional view of the refrigerator according to the second embodiment of the present invention along the line AA (in FIG. 1).

  The dew prevention pipe 23 and the condenser pipe 24 of the outer plate 11 are thermal heat radiating pipes constituting a refrigeration cycle (not shown).

  The vacuum heat insulating material 45 is a vacuum heat insulating material that is installed in the foam heat insulating material 13 such as urethane and has better heat insulating performance than the foam heat insulating material 13, and the heat of the dew prevention pipe 23 and the condenser pipe 24 is stored in the refrigerator. The pipes 23 and 24 are covered so as not to enter the inside, and are fixed to the inner surface 21a of the side plate 21 with an adhesive or the like.

The vacuum heat insulating material 45 includes a core material 45a and a jacket material 48 that covers the core material and has a gas barrier layer.
The core material 45a includes a core material 46 serving as a strength member of the core material, and a coating layer 47 that covers the surface of the core material. The coating layer 47 is arranged so that the core material 46 and the jacket material 48 are not in direct contact with at least the surface of the surface of the core material 46 where the dew prevention pipe 23 or the condenser pipe 24 and the vacuum heat insulating material 45 are in contact. The surface of the core material 46 is covered.
The core material 46 is a plate-like fiber material provided with an inorganic binder such as boric acid or phosphoric acid, and the coating layer 47 is a flexible fiber material.

  Therefore, even if the surface of the core material 46 is cured by an inorganic binder, the coating layer 47 that is a flexible fiber material absorbs dimensional errors in manufacturing, and the vacuum heat insulating material 45 is used to prevent dew condensation. 23 and the condenser pipe 24 are covered with each other, and can be in close contact with the inner surface 21a of the side plate 21.

  The grooves 45b and 45c provided on the surface of the vacuum heat insulating material 45 have such a size and dimensions that the unevenness of the dew prevention pipe 23 and the condenser pipe 24 can be absorbed by the flexible covering layer of the vacuum heat insulating material. However, the dimensions are set so that the foam insulation does not enter.

  A manufacturing dimensional error and a molding error occur in the shape dimensions of the grooves 45b and 45c and the outer diameter dimensions of the dew prevention pipe 23 and the condenser pipe 24.

  Therefore, in the present invention, the periphery of the grooves 45b and 45c formed on the surface of the vacuum heat insulating material is covered with a coating layer 47 formed of a flexible fiber material, and the irregularities and dimensions of the outer diameter of the thermal heat radiation pipe are measured. The error can be absorbed.

  There are roughly two methods for manufacturing the grooves 45b and 45c. A method of forming the surfaces of the core material 46 and the coating layer 47 in a concave shape in advance, and the surfaces of the core material 46 and the coating layer 47 are manufactured in a flat shape in the initial manufacturing stage and completed as a vacuum heat insulating material. 45c is formed by pressing or roller pressing.

  From the viewpoint of manufacturing efficiency of the refrigerator, it is advantageous to manufacture a plurality of flat plate vacuum heat insulating materials having predetermined dimensions and form grooves 45b and 45c by post-processing according to the use of each vacuum heat insulating material. .

  When the vacuum heat insulating material of the present invention is employed, when the grooves 45b and 45c are formed by pressing or roller pressing, even if press pressure or roller pressure is applied to the outer covering 48, the back surface of the outer covering 48 is flexible. Therefore, the gas barrier layer of the jacket material 48 is less likely to be damaged.

  In Example 2 of the refrigerator, the thickness dimension T41 of the coating layer 47 of the vacuum heat insulating material 45 is illustrated. The thickness dimension T41 of the covering layer 47 is set larger than the pipe outer diameter dimension of the dew prevention pipe 23 and the condenser pipe 24. Therefore, the core material 46 of the vacuum heat insulating material 45 can be manufactured to have a substantially flat surface. Therefore, the fibers of the core material 46 are not divided by the groove processing, so that the heat insulating performance is not deteriorated. Manufacturing efficiency is improved.

  Since the outer diameter of the dew prevention pipe 23 and the condenser pipe 24 is normally set to about 2 mm to 6 mm, the dimension T41 is preferably about 3 mm to 8 mm. Moreover, since the thickness T40 of the vacuum heat insulating material 45 is normally set to about 7 mm to 40 mm, the thickness T43 of the core material 46 serving as a strength member of the core material is set to about 4 mm to 32 mm. Therefore, the strength of the core material 46 is ensured, the core material 46 is easy to handle, and the vacuum heat insulating material 45 containing the core material is also easy to handle.

  In the second embodiment of the refrigerator, there is a coating layer 47 formed of a flexible fiber material on the back surface of the outer cover material of the grooves 45b and 45c formed so as to cover the dew prevention pipe 23 and the condenser pipe 24. In addition, it is possible to absorb the manufacturing dimensional error of the grooves 45b and 45c, and even if the dew prevention pipe 23 and the condenser pipe 24 are pressed against the grooves 45b and 45c, the gas barrier property of the jacket material is hardly impaired.

  Moreover, since the coating layer 47 should just be formed only in the single side | surface of a plate-shaped core material, the refrigerator advantageous in terms of manufacturing cost can be provided.

(Example 3 of refrigerator)
FIG. 8 is a cross-sectional view of a third embodiment of the refrigerator according to the present invention.

  The heat insulation wall 26 such as a refrigerator box or door is composed of an outer plate 27, an inner plate 28, and a foam heat insulating material 29 such as urethane filled between the outer plate 27 and the inner plate 28. The vacuum heat insulating material 55 is fixed to the outer plate 27 with a hot-melt adhesive or an adhesive tape. The vacuum heat insulating material 55 includes a core material 55a and a gas barrier outer covering material 58 that covers the core material 55a. The core material 55 a is a fiber material with an inorganic binder, and includes a core material 56 that is a strength member of the core material and a covering layer 57. The covering layer 57 is a flexible fiber material, and the outer cover material 58a on the side to be attached to the outer plate 27 and the outer plate 27 are in close contact with each other, and the outer layer 27 is in close contact with the outer plate 27. A flexible coating layer 57 is interposed between the core material 56 and the jacket material 58a so that the material 58a does not directly contact the core material 56. As a result of the outer plate 27 and the vacuum heat insulating material 55 being in close contact with each other due to the flexibility of the covering layer 57, the foam heat insulating material such as urethane cannot enter between the outer plate 27 and the vacuum heat insulating material 55.

  For the purpose of enhancing the appearance design of the refrigerator, when the surface layer 27a of the heat insulating wall 26 is formed of a thin plate, and the foam insulating material such as urethane is filled in the heat insulating wall 26, the foaming pressure of urethane or the like In some cases, the surface of the thin plate surface layer 27a may be curved so as to reduce the slack.

  The outer plate formed into a curved surface for the above purpose and the vacuum heat insulating material 55 are in close contact so that a foam heat insulating material such as urethane does not enter between the thin plate surface layer 27a of the outer plate and the vacuum heat insulating material 55. The thickness T8 of the covering layer 57 is set in consideration of the curved surface dimension T9.

In the third embodiment of the refrigerator, the coating layer 57 on the side in contact with the outer plate of the vacuum heat insulating material 55 is formed of a flexible fiber material, and the core material surface 56 that is cured by a binder and has unevenness on the surface is coated with flexibility. Since the layer covers, the flatness of the vacuum heat insulating material 55 can be easily obtained, and a foam heat insulating material such as urethane does not easily enter between the vacuum heat insulating material 55 and the outer plate 27, and the surface of the outer plate is less distorted and uneven. An external refrigerator can be provided.
In addition, since the flexible coating layer can be adhered and adhered to the curved surface portion of the outer plate having a curved surface, the curved surface portion is formed into a beautiful curved shape as originally planned, so that the external appearance design is not impaired. The design freedom of the designer is greatly improved.

(Example 1 of the manufacturing method of a vacuum heat insulating material)
FIG. 9 is a diagram showing manufacturing steps in Example 1 of the method for manufacturing a vacuum heat insulating material according to the present invention.

  Pretreatment: Core material forming step: The core material raw material 61 is formed by a core material forming step in which a raw material made of a fiber material laminate is attached with a binder to form. In order to create the core material 61, for example, “artificial mineral fiber heat insulating material” (JISA9504) is used as raw cotton, a predetermined number of raw cottons are laminated, and impregnated with an inorganic binder liquid such as boric acid or phosphoric acid. When the inorganic binder in the raw cotton reaches a predetermined impregnation rate, the raw cotton is hot-pressed and cut into predetermined dimensions.

  Pretreatment: Cover layer forming step: The raw material 62 of the cover layer is a flexible fiber material. For example, using “artificial mineral fiber heat insulating material” (JISA9504) as raw cotton, the core material 61 has a rectangular shape. Cut into predetermined dimensions large enough to cover each side.

  FIG. 9A: Covering process: Covering and covering each surface of the core material 61 formed in the core material forming process by the long side surfaces 62a and 62b of the flexible coating layer material 62.

  FIG. 9B: Drying step: The core material raw material 63 formed in the coating step is dried for 10 to 60 minutes in a drying furnace at 110 to 250 ° C., for example.

  FIG. 9 (c): welding process: the core material 63 formed through the coating process and the drying process is sandwiched in the jacket material 64. The jacket material 64 is made of a gas barrier laminate film. In order to sandwich the core material 63 in the jacket material 64, a method of inserting the core material 63 into the bag-shaped jacket material 64, or a core material material 63 between the sheet-like jacket materials 64. A continuous molding method or the like is used in which each side of the two jacket materials is welded. After the core material 63 is sandwiched between the jacket materials 64, a laminate film is welded.

  FIG. 9 (d): Depressurization sealing process: The vacuum jacket material 64 and the core material 63 prepared are decompressed to a predetermined degree of vacuum, the inlet 64a of the jacket material is sealed, and vacuum insulation is performed. A material 65 is created.

  The vacuum heat insulating material 65 includes a core material 65a in which the inside of the core material 63 is sealed under reduced pressure, and a gas barrier coating material 68 in which the inside of the jacket material 64 covering the core material 65a is sealed under reduced pressure. The core material 65a is formed of a fiber material with an inorganic binder that serves as a strength member of the core material, and the core material 66 is sealed with reduced pressure inside the core material raw material 61. The core material 65a is formed of a flexible fiber material that covers the surface of the core material. It comprises a coating layer 67 in which the inside of the layer raw material 62 is sealed under reduced pressure.

  The ear 65c is an ear that is formed on the edge of the bag-shaped outer covering material 64 by compressing the core material raw material 63 to a predetermined thickness when the pressure is reduced to a predetermined degree of vacuum. When the space around the vacuum heat insulating material 65 is filled with a urethane foam heat insulating material or the like, the ear 65c is often bent because the filling flow of the urethane foam heat insulating material is hindered.

  FIG. 9 (e): Ear folding step: Folding is performed so as to be in close contact with the outer surface of the vacuum heat insulating material 65, thereby forming an adhesive ear 65 d.

  FIG. 9 (f): Application process: The application member 72 such as an adhesive tape or hot melt adhesive is uniformly applied to an arbitrary surface 65 f of the vacuum heat insulating material 65 by the application roller 72 and the support roller 73.

  FIG. 9G: Affixing step: Using a pressure roller 74 or the like, the arbitrary surface 65f of the vacuum heat insulating material 65 is affixed to the outer plate of the refrigerator or the back surface 75a of the door outer plate 75, and the vacuum heat insulating material 65 is attached to the refrigerator. Secure inside the insulation wall.

  The vacuum heat insulating material 65 having such a structure is easy to handle in the manufacturing process of the vacuum heat insulating material itself because the core material 66 hardened by the binder does not contact the outer cover material 68.

  As shown in FIGS. 9A, 9B and 9C, the surface of the core material 61 cured with the binder is covered with the coating material 62 to form the core material 63. At the time of transportation or storage during storage, fine powder generated from the surface of the core raw material 61 hardened by the binder is adsorbed by the raw material of the flexible coating layer and does not pollute the surrounding work environment. This also makes it easier to handle in the manufacturing process.

  As shown in FIG. 9 (c), when the core material raw material 63 is installed in the jacket material 64, the surface of the core material raw material 61 has material particles, foreign matter or wrinkles hardened by the binder, or Even if there is a corner or ridge knife edge generated by cutting the core material 61, the core material 61 is covered with the material 62 of the flexible coating layer, so that the jacket material 64 is less likely to be damaged.

Also, in the continuous molding method in which the outer cover material 64 is formed into two sheets and the core material raw material 63 is disposed between the sheet-shaped outer cover materials, and then each side of the two sheets is welded. Since the raw material 61 is covered with the raw material 62 of the flexible coating layer, the same effect can be obtained. As shown in FIG. 9D, the inside of the jacket of the vacuum heat insulating material is depressurized to a predetermined degree of vacuum. In this case, a large pressure that is relatively close to the atmospheric pressure is applied to the outer surface of the jacket material. If the surface of the core material 66 has material particles, foreign matter, or wrinkles cured by a binder, or if there is a corner or ridge knife edge generated by cutting the core material 66, the outer cover material may be damaged. was there.

  On the other hand, in the present invention, a flexible coating layer 67 is interposed between the core material 66 and the jacket material 68 so that the core material 66 and the jacket material 68 do not directly contact each other. The outer covering material 64 is hardly damaged and is easy to handle.

  As shown in FIG. 9E, when the ear 65c is folded back so as to be in close contact with the outer surface of the vacuum heat insulating material 65 to form the close ear 65d, the close ear 65d is pressed against the vacuum heat insulating material. The corners and ridge lines 68b of the material 68 are strongly pressed against the corners and ridge lines 66b of the core material 66 cured by the binder. Accordingly, when the corner or ridge line portion 66b of the core material 66 has a knife edge, the outer covering material 68 may be damaged.

  On the other hand, in the present invention, the flexible covering layer 67b is interposed so that the corners and the ridgeline part 66b of the core material 66 and the corners and the ridgeline part 68b of the covering material 68 are not in direct contact. Therefore, the outer covering material 68b is hardly damaged and the handling becomes easy.

  As shown in FIGS. 9F and 9G, when the vacuum heat insulating material 65 is processed using the application roller 72, the support roller 73, the pressure roller 74, etc., a large pressing force is applied to the vacuum heat insulating material 68c. Therefore, when there are material particles, foreign matter or wrinkles hardened by the binder on the surface of the core material 66c, or when there is a corner or ridge knife edge generated by cutting the core material 66c, the jacket material Could be damaged.

  On the other hand, in the present invention, the flexible coating layer 67c is interposed between the core material 66c and the jacket material 68c so that the core material 66c and the jacket material 68c are not in direct contact with each other. In addition, it is possible to obtain a vacuum heat insulating material that is less likely to damage the gas barrier layer of the bag-shaped outer covering material 64 and is easy to handle in each manufacturing process when the vacuum heat insulating material 68 is incorporated into a refrigerator box or a door.

(Example 2 of the manufacturing method of a vacuum heat insulating material)
FIG. 10 is a diagram showing manufacturing steps in Example 2 of the method for manufacturing a vacuum heat insulating material according to the present invention.

  In FIG. 10A, a fiber material 81 is a flexible fiber material using “artificial mineral fiber heat insulating material” (JISA9504), and is a coating layer raw material cut into a predetermined size. The core material 82 uses “artificial mineral fiber heat insulating material” (JISA9504) as a raw cotton, and after a predetermined number of raw cottons are laminated, an inorganic binder liquid such as boric acid or phosphoric acid is applied only to one surface 82a of the core. The raw material.

  First, as shown in FIG. 10 (b), it is folded in half with the surface 82a coated with the inorganic binder liquid facing inside.

  Next, as shown in FIG. 10 (c), a core material 82 is covered with a flexible coating layer material 81 from above and below a core material 82 that is coated with an inorganic binder solution and folded in half to obtain a core material 83.

  Thereafter, this core material raw material 83 is used, and a vacuum heat insulating material is completed by the same manufacturing process as in FIGS. 9C to 9G of Example 1 of the manufacturing method.

  According to Example 2 of the manufacturing method of a vacuum heat insulating material, since the surface hardened by the binder exists only on the center surface 82a of the core material as shown in FIG. 10C, the fiber molded body of the core material surface layer Therefore, the solid thermal conductivity of the surface layer of the core material is reduced, and the heat insulating performance as a vacuum heat insulating material is increased.

  In addition, since there are few coalescence states of the fiber molded body of the core material surface layer, the exhaust resistance during vacuum evacuation decreases, and the degree of vacuum inside the vacuum heat insulating material tends to decrease. This shortens the productivity of the vacuum heat insulating material.

It is a longitudinal cross-sectional view which shows the Example of the refrigerator by this invention. It is a cross-sectional view which followed the AA line in FIG. 1 of Example 1 of the refrigerator by this invention. It is sectional drawing which shows the structure of the vacuum heat insulating material by this invention. It is an expanded sectional view which shows the structure of the principal part of the vacuum heat insulating material of FIG. It is a graph which shows the characteristic value of an artificial mineral fiber heat insulating material. It is a graph which compares and shows the characteristic of Example 1, Example 2, and Comparative Example 1 of the vacuum heat insulating material by this invention. It is a cross-sectional view along the AA line (in FIG. 1) of the second embodiment of the refrigerator according to the present invention. It is a cross-sectional view of Example 3 of the refrigerator according to the present invention. It is a figure which shows the manufacturing process in Example 1 of the manufacturing method of the vacuum heat insulating material by this invention. It is a figure which shows the manufacturing process in Example 2 of the manufacturing method of the vacuum heat insulating material by this invention. It is sectional drawing which shows the structure of the conventional core material.

Explanation of symbols

2 Core material 2a Material grain 2b Foreign matter 2c Wrinkle 2e Surface 10 Refrigerator box body 11 Outer plate 12 Inner plate 12a Flange 13 Foam heat insulating material 14 Refrigeration temperature chamber 15 Refrigeration temperature chamber 16 Blower 17 Wiring cord 18 Cooler 19 Piping 20 Compressor 21 Side plate 21a Front fitting portion 21b, 21c Rear fitting portion 22 Back plate 22a Flange 23 Dew prevention pipe 24 Condenser pipe 25 Reinforcement member 25a Locking tool 26 Heat insulation wall 27 Outer plate 27a Surface layer 28 Inner plate 29 Foam insulation Materials 30, 40, 45, 55, 65 Vacuum insulation materials 30a, 40a, 45a, 65a Core material 30b Ridge line portions 31, 41, 46, 56, 66 Core material 31b Foreign material 31c Wrinkle 31e Surfaces 32, 42, 47, 57. 67 Coating layer 33, 43, 48, 58, 68 Cover material 33a Surface protection film 33b Metal vapor deposition film 33c Support layer 3 3e Metal foil 33f Welding film layer 41c Wrinkle 45 Vacuum heat insulating material 45a Core material 45b, 45c Groove 55a Core material 61 Core material raw material 62 Cover layer raw material 62a Long side surface 62b Long side surface 63 Core material raw material 64 Bag-shaped outer covering material 64a Entrance 65a Core material 65c Ear 65d Adhesion ear 65f Arbitrary surface 66b Corner / ridge line portion 66c Core material 67b, 67c Cover layer 68b, 68c Cover material 71 Adhesive member 72 Application roller 73 Support roller 74 Pressure roller 75 Door outer plate 75a Back surface 81 Textile material 82 Core material raw material 82a Application surface / center surface 83 Core material raw material H Dimension T Thickness

Claims (12)

In a vacuum heat insulating material consisting of a core material and a jacket material covering the core material,
The core material is composed of a core material of a fiber material laminate and a flexible fiber material coating layer,
A vacuum heat insulating material, wherein the core material formed by covering the core material with the coating layer is disposed in the jacket material. In a vacuum heat insulating material consisting of a core material and a jacket material covering the core material,
The core material is composed of a core material of a fiber material laminate and a flexible fiber material coating layer,
The core material is a core material formed by applying an inorganic binder solution and thermoforming,
A vacuum heat insulating material, wherein the core material formed by covering the core material with the coating layer is disposed in the jacket material. In the vacuum heat insulating material according to claim 1 or 2,
A vacuum heat insulating material, wherein the coating layer has a thickness of 1 mm or more. In the vacuum heat insulating material as described in any one of Claims 1 thru | or 3,
A vacuum heat insulating material, wherein the jacket material comprises a welded film layer having a thickness of 50 μm or less. In the vacuum heat insulating material as described in any one of Claim 1 thru | or 4,
A vacuum heat insulating material, wherein the core material is a molded body of waste fiber material. In the vacuum heat insulating material as described in any one of Claim 1 thru | or 4,
The vacuum heat insulating material, wherein the core material is a board-like molded body made of continuous urethane or waste urethane. In the method of manufacturing a vacuum heat insulating material comprising a core material and a jacket material covering the core material,
Covering the core material of the fiber material laminate with a coating layer of a flexible fiber material to form the core material,
Placing the core material in the jacket material;
A method for manufacturing a vacuum heat insulating material, wherein the inside of the outer jacket material is sealed under reduced pressure. In the method of manufacturing a vacuum heat insulating material comprising a core material and a jacket material covering the core material,
Impregnated with an inorganic binder solution and pressed to create a core material for the fiber material laminate,
Create a coating layer with a flexible fiber material of a size covering the core material,
Covering with a covering layer of flexible fiber material to form the core material,
Drying the core material at a predetermined temperature;
Insert the core material into the jacket material made of a laminate film,
A method for manufacturing a vacuum heat insulating material, wherein the inside of the outer jacket material is sealed under reduced pressure. In the refrigerator that fixes the vacuum heat insulating material on the outer plate side or the inner plate side of the space formed by the outer plate and the inner plate, and fills the space other than the vacuum heat insulating material with a foam heat insulating material to form a heat insulating wall,
The said vacuum heat insulating material is a vacuum heat insulating material as described in any one of Claim 1 thru | or 5, The refrigerator characterized by the above-mentioned. The refrigerator according to claim 9,
A thermal heat radiating pipe is provided between the outer plate and the vacuum heat insulating material,
A refrigerator characterized in that irregularities of the outer diameter of the thermal heat radiation pipe are absorbed by a flexible coating layer of the vacuum heat insulating material. The refrigerator according to claim 9,
In the vicinity of the vacuum heat insulating material has a projection other than the vacuum heat insulating material,
The refrigerator characterized by providing the said coating layer only on the surface of the said core material, or a corner | angular line, or a ridgeline with which the said protrusion may contact | abut. The refrigerator according to claim 9,
The refrigerator, wherein the vacuum heat insulating material is installed on the outer plate side in the heat insulating wall, and the coating layer is formed only on the side of the vacuum heat insulating material in contact with the outer plate.

Images